Phosphors and lighting apparatus using the same

ABSTRACT

A phosphor has a chemical formula of: A m (Ba 1-x Eu x ) n P y O z , wherein A is at least one of the group consisting of Li, Na and K, while 0&lt;m&lt;10, 0&lt;n&lt;10, 0&lt;y&lt;10, m+n+y=3/4 z, and 0.001&lt;x&lt;0.8.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates to phosphors and, more particularly, tophosphors for use in a lighting apparatus.

2. Description of Related Art

Semiconductor lighting apparatuses include light-emitting diodes (LEDs)and laser diodes. Semiconductor lighting apparatuses which provideultraviolet or near ultraviolet light can be used in combination withdifferent phosphors to make various kinds of light sources.

Of all the new products in the LED industry, white light-emitting diodeshave the greatest potential in commoditization and popularizationbecause they provide such advantages as having a small size, low heatgeneration, low energy consumption and long glowing persistence.Therefore, white light-emitting diodes can be applied to theillumination for daily use and hopefully replace fluorescent lamps andthe conventional light sources used in the back lights of flat-paneldisplays. The so-call “white light” is in fact a combination of variouscolor lights. A white light visible to human eyes must comprise acombination of at least two categories of lights of different colors,such as a combination of blue and yellow lights or a combination ofgreen, blue and red lights.

Presently, most of the commercial white lighting apparatuses generate awhite light by using a phosphor powder of Y₃Al₅O₁₂:Ce (YAG:Ce), whichemits a yellow light when excited and combined with a blue LED. Thiscommercial yellow-emitting phosphor powder is prepared through asolid-state sintering reaction at a high temperature ranging from 1400°C. to 1600° C., and can be excited by a blue LED having an emissionwavelength of 467 nm to produce a yellow light having an emission lightof 550 nm, whose CIE chromaticity coordinate is (0.48, 0.50).

This yellow-emitting phosphor powder for use with a blue LED issynthesized under a strict condition, namely, through a solid-statesintering reaction at a relatively high temperature. Moreover, thisyellow-emitting phosphor powder shows a poor color rendering propertywhen used in a white-light lighting apparatus because the powder emits alight that lacks a blue light component.

As to the commercial blue-emitting phosphor powder,(Ba_(0.8)Eu_(0.2))MgAl₁₀O₁₇ (abbreviated as BAM) of Kasei Optonix, aJapanese phosphor company, has the widest applications. In addition toapplication in semiconductor lighting apparatuses, BAM is indispensablein plasma display devices. However, BAM has such disadvantages as ashort glowing persistence and being unstable under an ultraviolet light.Still worse, the maximal emission wavelength of BAM tends to shifttowards a longer wavelength during the manufacturing process, so thatthe color performance of BAM is biased to a green light and thus resultsin a lower color purity.

BRIEF SUMMARY OF THE INVENTION

A primary objective of the present invention is to provide a series ofphosphors having novel compositions.

A second objective of the present invention is to provide a series ofphosphors that can be excited by an ultraviolet light, a nearultraviolet light and a blue light, and provide a blue light radiationsource when excited.

A third objective of the present invention is to provide a lightingapparatus, wherein a semiconductor light source is used in combinationwith a phosphor so that the lighting apparatus is applicable to a cellphone panel, an automobile headlight and an illuminating apparatus fordaily use.

To achieve these ends, the present invention provides a series ofphosphors having a chemical formula of:A_(m)(Ba_(1-x)Eu_(x))_(n)P_(y)O_(z), wherein A is at least one of thegroup consisting of Li, Na and K, while 0<m<10, 0<n<10, 0<y<10,m+n+y=3/4 z, and 0.001<x<0.8.

The present invention further provides a lighting apparatus comprising asemiconductor light source and a phosphor, which has a chemical formulaof: A_(m)(Ba_(1-x)Eu_(x))_(n)P_(y)O_(z), wherein A is at least one ofthe group consisting of Li, Na and K, while 0<m<10, 0<n<10, 0<y<10,m+n+y=3/4 z, and 0.001<x<0.8.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The invention as well as a preferred mode of use, further objectives andadvantages thereof will best be understood by reference to the followingdetailed description of illustrative embodiments when read inconjunction with the accompanying drawings, wherein:

FIG. 1 shows X-ray powder diffraction patterns ofLi(Ba_(0.99)Eu_(0.01))PO₄ according to a first preferred embodiment ofthe present invention;

FIG. 2 shows X-ray powder diffraction patterns ofNa(Ba_(0.99)Eu_(0.01))PO₄ according to a second preferred embodiment ofthe present invention;

FIG. 3 shows X-ray powder diffraction patterns ofK(Ba_(0.99)Eu_(0.01))PO₄ according to a third preferred embodiment ofthe present invention;

FIG. 4 shows excitation and emission spectra ofLi(Ba_(0.99)Eu_(0.01))PO₄ according to the first preferred embodiment ofthe present invention;

FIG. 5 shows excitation and emission spectra ofNa(Ba_(0.99)Eu_(0.01))PO₄ according to the second preferred embodimentof the present invention;

FIG. 6 shows the excitation and emission spectra ofK(Ba_(0.99)Eu_(0.01))PO₄ according to the third preferred embodiment ofthe present invention;

FIG. 7 shows a comparison of excitation and emission spectra betweenLi(Ba_(0.99)Eu_(0.01))PO₄ according to the first preferred embodiment ofthe present invention and the commercially available phosphor product of(Ba_(0.8)Eu_(0.2))MgAl₁₀O₁₇;

FIG. 8 shows a comparison of excitation and emission spectra betweenNa(Ba_(0.99)Eu_(0.01))PO₄ according to the second preferred embodimentof the present invention and the commercially available phosphor productof (Ba_(0.8)Eu_(0.2))MgAl₁₀O₁₇;

FIG. 9 shows a comparison of excitation and emission spectra betweenK(Ba_(0.99)Eu_(0.01))PO₄ according to the third preferred embodiment ofthe present invention and the commercially available phosphor product of(Ba_(0.8)Eu_(0.2))MgAl₁₀O₁₇; and

FIG. 10 shows a comparison of CIE chromaticity coordinates betweenLi(Ba_(0.99)Eu_(0.01))PO₄, Na(Ba_(0.99)Eu_(0.01))PO₄ andK(Ba_(0.99)Eu_(0.01))PO₄ according to the preferred embodiments of thepresent invention and the commercially available phosphor product of(Ba_(0.8)Eu_(0.2))MgAl₁₀O₁₇.

DETAILED DESCRIPTION OF THE INVENTION

A detailed description of the present invention will be given below withreference to preferred embodiments thereof, so that a person skilled inthe art can readily understand features and functions of the presentinvention after reviewing the content disclosed herein. The presentinvention can be carried out or applied in other embodiments, wherechanges and modifications can be made to the details disclosed hereinfrom a viewpoint different from that adopted in this specificationwithout departing from the spirit of the present invention.

Phosphors according to the present invention are prepared through asolid-state reaction at a high temperature. A preferred embodiment ofthe present invention is Na(Ba_(1-x)Eu_(x))PO₄, which is prepared by amethod comprising the following steps. To begin with, barium carbonate(BaCO₃), sodium carbonate (Na₂CO₃), europium sesquioxide (Eu₂O₃) anddiammonium hydrogen phosphate ((NH₄)₂HPO₄) are weighedstoichiometrically, followed by thorough mixing and then ground for tenminutes. Next, the resultant mixture is put into a crucible and placedin a high-temperature furnace to fire in air at a temperature rangingfrom about 1000° C. to about 1300° C. for several hours. Following that,the sintered product is put into an alumina boat and placed in ahigh-temperature tube furnace to refire in a mixed atmosphere ofhydrogen and argon at a temperature ranging from about 700° C. to about950° C. for four to seven hours. The final product is a phosphoraccording to the present invention.

In the method described above, sodium carbonate (Na₂CO₃) can be replacedby various metal salts such as lithium carbonate (Li₂CO₃) or potassiumcarbonate (K₂CO₃). Accordingly, using different metal salts may producethe phosphors of the present invention, i.e.,A_(m)(Ba_(1-x)Eu_(x))_(n)P_(y)O_(z), wherein A is at least one of thegroup consisting of Li, Na and K, while 0<m<10, 0<n<10, 0<y<10,m+n+y=3/4 z, and 0.001<x<0.8.

FIGS. 1, 2, and 3 represent the X-ray powder diffraction patterns of theproducts of the preferred embodiments of the present invention,Li(Ba_(0.99)Eu_(0.01))PO₄, Na(Ba_(0.99)Eu_(0.01))PO₄ andK(Ba_(0.99)Eu_(0.01))PO₄, respectively, which are all prepared by themethod mentioned above. The comparison on the X-ray diffraction profilesbetween the crystalline phase of said products and the relevantliterature database confirm that the main substances of the products ofthe present invention do have the same crystal structures of LiBaPO₄,NaBaPO₄ and KBaPO₄.

Referring to FIG. 4, a fluorescence spectrophotometer was used tomeasure the excitation and emission spectra ofLi(Ba_(0.99)Eu_(0.01))PO₄, which was prepared as one of the preferredembodiment of the present invention. It is shown thatLi(Ba_(0.99)Eu_(0.01))PO₄ provided by the present invention has anabsorption band with wavelength ranging from about 250 nm to about 420nm, wherein a maximal absorption peak occurs at about 346 nm.Furthermore, Li(Ba_(0.99)Eu_(0.01))PO₄ has an emission band withwavelength ranging from about 400 nm to about 600 nm, wherein a maximalemission peak occurs at about 475 nm. FIG. 4 clearly demonstrates thatLi(Ba_(0.99)Eu_(0.01))PO₄ can be excited by an ultraviolet light, a nearultraviolet light or a blue light, and emits a blue light when excited.

Referring to FIG. 5, the fluorescence spectrophotometer was used toproduce the excitation and emission spectra ofNa(Ba_(0.99)Eu_(0.01))PO₄, which was prepared as another preferredembodiment of the present invention. It is shown thatNa(Ba_(0.99)Eu_(0.01))PO₄ provided by the present invention has anabsorption band whose wavelength ranges from about 250 nm to about 420nm, wherein a maximum-absorption peak occurs at a wavelength of about352 nm. Furthermore, Na(Ba_(0.99)Eu_(0.01))PO₄ has an emission bandwhose wavelength ranges from about 400 nm to about 550 nm, wherein amaximum-emission peak occurs at a wavelength of about 434 nm. FIG. 5clearly demonstrates that Na(Ba_(0.99)Eu_(0.01))PO₄ can be excited by anultraviolet light, a near ultraviolet light or a blue light, and emits ablue light when excited.

Referring to FIG. 6, the fluorescence spectrophotometer was used toproduce the excitation and emission spectra of K(Ba_(0.99)Eu_(0.01))PO₄,which was prepared as yet another preferred embodiment of the presentinvention. It is shown that K(Ba_(0.99)Eu_(0.01))PO₄ provided by thepresent invention has an absorption band whose wavelength ranges fromabout 250 nm to about 420 nm, wherein a maximum-absorption peak occursat a wavelength of about 348 nm. Furthermore, K(Ba_(0.99)Eu_(0.01))PO₄has an emission band whose wavelength ranges from about 400 nm to about500 nm, wherein a maximum-emission peak occurs at a wavelength of about419 nm. FIG. 6 clearly demonstrates that K(Ba_(0.99)Eu_(0.01))PO₄ can beexcited by an ultraviolet light or a near ultraviolet light, and emits ablue light when excited.

FIGS. 7 to 9 show a comparison of the excitation and emission spectraamong Li(Ba_(0.99)Eu_(0.01))PO₄, Na(Ba_(0.99)Eu_(0.01))PO₄ andK(Ba_(0.99)Eu_(0.01))PO₄ according to the preferred embodiments of thepresent invention and the commodity phosphor (Ba_(0.8)Eu_(0.2))MgAl₁₀O₁₇from Kasei Optonix. It is shown that the three phosphors preparedaccording to the present invention have emission intensities andbrightness similar to those of the commercial product,(Ba_(0.8)Eu_(0.2))MgAl₁₀O₁₇. Furthermore, the phosphors of the presentinvention have broader excitation bands than (Ba_(0.8)Eu_(0.2))MgAl₁₀O₁₇does, and are therefore more suitable for use with ultraviolet or nearultraviolet-pumped diodes.

FIG. 10 shows a comparison of CIE chromaticity coordinates amongLi(Ba_(0.99)Eu_(0.01))PO₄, Na(Ba_(0.99)Eu_(0.01))PO₄ andK(Ba_(0.99)Eu_(0.01))PO₄ according to the preferred embodiments of thepresent invention and the commodity phosphor (Ba_(0.8)Eu_(0.2))MgAl₁₀O₁₇from Kasei Optonix. It is shown that the phosphors of the presentinvention have higher color purities than the commodity phosphor(Ba_(0.8)Eu_(0.2))MgAl₁₀O₁₇ does.

Therefore, the phosphors according to the present invention can beapplied to a lighting apparatus comprising a semiconductor light sourcesuch as an LED or a laser diode, wherein the semiconductor light sourceemits an ultraviolet light or a near ultraviolet light. When thesemiconductor light source is used in combination with the phosphors ofthe present invention, the lighting apparatus emits a blue light.

This lighting apparatus can emit a white light or a light similar to thewhite light if the lighting apparatus further comprises a red-emittingphosphor and a green-emitting phosphor, wherein the red-emittingphosphor can be (Sr,Ca)S:Eu²⁺, (Y,La,Gd,Lu)₂O₃:Eu³⁺,Bi³⁺,(Y,La,Gd,Lu)₂O₂S:Eu³⁺,Bi³⁺, Ca₂Si₅N₈:Eu²⁺ or (Zn,Cd)S:Ag,Cl, while thegreen-emitting phosphor can be ZnS:Cu or BaMgAl₁₀ ₁₇Eu²⁺.

In summary, the phosphors according to the present invention have notonly novel compositions but also broad excitation bands (spanning froman ultraviolet to a blue light region), and are therefore suitable foruse in combination with commercially available ultraviolet LED chips.Furthermore, the phosphors according to the present invention can beused in the production of various lighting apparatuses, and moreparticularly a white-light lighting apparatus if the phosphors accordingto the present invention are used in combination with a red-emittingphosphor and a blue-light phosphor.

The preferred embodiments of the present invention have been providedfor illustrative purposes only and are not intended to limit the scopeof the present invention in any way. Moreover, as the content disclosedherein should be readily understood and can be implemented by a personskilled in the art, all equivalent changes or modifications which do notdepart from the spirit of the present invention are encompassed by theappended claims.

1. A phosphor having a chemical formula of:A_(m)(Ba_(1-x)Eu_(x))_(n)P_(y)O_(z), wherein A is at least one of groupconsisting of Li, Na and K, while 0<m<10, 0<n<10, 0<y<10, m+n+y=3/4 z,and 0.001<x<0.8.
 2. The phosphor as claimed in claim 1, wherein thephosphor can be excited by an ultraviolet light or a near ultravioletlight.
 3. The phosphor as claimed in claim 2, wherein the phosphor emitsa blue light when excited.
 4. The phosphor as claimed in claim 1,wherein the phosphor can be excited by a radiation source having awavelength ranging from about 250 nm to about 400 nm, and, when excited,emits light with wavelength ranging from about 400 nm to about 600 nm.5. The phosphor as claimed in claim 4, wherein the phosphor emits a bluelight when excited.
 6. The phosphor as claimed in claim 1, wherein thephosphor is prepared through a two-stage solid-state reaction comprisinga first step and a second step, wherein the first step comprisessintering in air at a temperature ranging from about 1000° C. to about1300° C., and the second step comprises sintering in an oxygen and argonatmosphere at a temperature ranging from about 700° C. to about 950° C.7. A phosphor having a chemical formula of:A(Ba_(0.99)Eu_(0.01))PO₄, wherein A is at least one of group consistingof Li, Na and K.
 8. The phosphor as claimed in claim 7, wherein thephosphor can be excited by an ultraviolet light or a near ultravioletlight.
 9. The phosphor as claimed in claim 8, wherein the phosphor emitsa blue light when excited.
 10. The phosphor as claimed in claim 7,wherein the phosphor can be excited by a radiation source having awavelength ranging from about 250 nm to about 430 nm, and, when excited,emits light with wavelength ranging from about 400 nm to about 600 nm.11. The phosphor as claimed in claim 10, wherein the phosphor emits ablue light when excited.
 12. The phosphor as claimed in claim 7, whereinthe phosphor is prepared through a two-stage solid-state reactioncomprising a first step and a second step, wherein the first stepcomprises sintering in air at a temperature ranging from about 1000° C.to about 1300° C., and the second step comprises sintering in a mixedatmosphere of hydrogen and argon at a temperature ranging from about700° C. to about 950° C.
 13. A lighting apparatus comprising: asemiconductor light source; and a phosphor which can be excited by thesemiconductor light source and has a chemical formula of:A_(m)(Ba_(1-x)Eu_(x))_(n)P_(y)O_(z), wherein A is at least one of groupconsisting of Li, Na and K, while 0<m<10, 0<n<10, 0<y<10, m+n+y=3/4 z,and 0.001<x<0.8.
 14. The lighting apparatus as claimed in claim 13,wherein the semiconductor light source comprises a light-emitting diode.15. The lighting apparatus as claimed in claim 13, wherein thesemiconductor light source comprises a laser diode.
 16. The lightingapparatus as claimed in claim 13, wherein the semiconductor light sourceemits an ultraviolet light or a near ultraviolet light.
 17. The lightingapparatus as claimed in claim 13, further comprising a red-emittingphosphor and a green-emitting phosphor.
 18. The lighting apparatus asclaimed in claim 17, wherein the red-emitting phosphor is (Sr,Ca)S:Eu²⁺,(Y,La,Gd,Lu)₂O₃:Eu³⁺,Bi³⁺, (Y,La,Gd,Lu)₂O₂S:Eu³⁺,Bi³⁺, Ca₂Si₅N₈:Eu²⁺ orZnCdS:AgCl.
 19. The lighting apparatus as claimed in claim 17, whereinthe green-emitting phosphor is ZnS:Cu or BaMgAl₁₀O₁₇Eu²⁺.
 20. Thelighting apparatus as claimed in claim 13, wherein the x in the chemicalformula of the phosphor has a value of 0.01.